Autonomous Vehicle Solution for Transporting 1-Ton Material Pallets to Replace Manual Forklifts

Project Overview

A major FMCG manufacturer sought to automate the transportation of material pallets within its factory to replace traditional manual forklifts. Their goals were to reduce labor costs, optimize transport flow, and enhance workplace safety. IDEA was chosen to provide an Autonomous vehicle solutions, Autonomous Guided Vehicle (AGV)/Autonomous Mobile Robot (AMR), capable of transporting pallets weighing up to 1 ton, ensuring seamless integration with their existing production management system.

Implementation

1. Handling heavy loads:
   • The autonomous vehicles needed to transport 1-ton pallets over long distances within the factory, maintaining high stability.
2. Non-disruptive implementation:
   • The system had to be deployed while the factory remained fully operational, requiring meticulous planning and coordination to avoid production disruptions.
3. Safety and precision:
   • The AGVs needed to avoid collisions, operate safely in crowded environments, and comply with international safety standards.

Solution

IDEA developed and implemented an autonomous pallet transport solution with the following key features:

1. Advanced navigation technology:
   • Leveraging SLAM (Simultaneous Localization and Mapping) technology with LIDAR sensors and cameras for intelligent navigation in complex factory environments.
   • AGVs could navigate narrow pathways and automatically avoid obstacles.
2. Custom design for heavy loads:
   • The AGVs were equipped with hydraulic lifting systems to handle and transport 1-ton pallets with ease and stability.
3. Superior safety features:
   • Integrated obstacle detection sensors, warning lights, alarm horns, and emergency stop functions.
   • Automatic speed reduction at blind corners and crowded areas.
4. Automated charging capabilities:
   • The system included automatic docking at charging stations when battery levels were low, ensuring uninterrupted operation without human intervention.

Implementation

1. Survey and planning:
   • Conducted a detailed factory layout survey and analyzed current transport flows to design optimal routes for the AGVs.
2. Production and deployment:
   • Manufactured AGVs and configured navigation software before testing and commissioning them in the factory.
3. Training and technology transfer:
   • Trained the client’s operational team on the usage, management, and maintenance of the AGV system.
4. Monitoring and optimization:
   • Monitored autonomous vehicle solution performance during the first two weeks and optimized travel routes based on real-time data.

Results

1. Increased transport efficiency:
   • Improved pallet transport efficiency by 35%, reducing downtime between production processes.
2. Lower operational costs:
   • Achieved 25% labor cost savings compared to manual forklifts.
3. Enhanced workplace safety:
   • Eliminated incidents related to manual forklifts, creating a safer work environment.
4. Eco-friendly operations:
   • AGVs powered by Lithium-ion batteries reduced emissions compared to internal combustion engine forklifts.

Clients Feedback

The Autonumous vehicle solution successfully optimized material flow, reducing reliance on manual labor. Contact us today to explore how IDEA can enhance your production efficiency with automation solutions.